Sustainable composite cylinder

Abstract

A composite cylinder assembly may comprise a tube liner including a first domed portion defining a first liner neck, a second domed portion defining a second liner neck, and a cylindrical wall. The cylinder assembly may comprise at least one port. The port may comprise an outer diameter configured to fit into an inner diameter of a liner neck and a lip including an outer diameter that is greater than the inner diameter of the liner neck. The port may comprise a swage recess having an outer diameter that is less than the inner diameter of the liner neck and may be configured to press-fit into the liner neck. The lip may be configured to provide a surface area to weld the port to the liner neck. The swage recess may be configured to provide an area to swage the liner neck to the port.

1 . A composite cylinder assembly, comprising:
 a tube liner, wherein the tube liner comprises:
 a first domed portion, wherein the first domed portion defines a first liner neck; 
 a second domed portion, wherein the second domed portion defines a second liner neck; and 
 a cylindrical wall coupled to the first domed portion and the second domed portion, wherein the cylindrical wall is between the first domed portion and the second domed portion; and 
   a first port, wherein the first port comprises an outer diameter configured to fit into an inner diameter of the first liner neck, wherein the first port further comprises:
 a first lip, wherein the first lip comprises an outer diameter that is greater than the inner diameter of the first liner neck; and 
 a first swage recess, wherein the first swage recess comprises an outer diameter that is less than the inner diameter of the first liner neck, 
   wherein the first port is configured to press-fit into the first liner neck, wherein the lip is configured to provide a surface area to weld the first port to the first liner neck, wherein the swage recess is configured to provide an area to swage the first liner neck to the first port.   
     
     
         2 . The composite cylinder assembly of  claim 1 , further comprising:
 a second port, wherein the second port comprises an outer diameter configured to fit into an inner diameter of the second liner neck, wherein the second port further comprises:
 a second lip, wherein the second lip comprises an outer diameter that is greater than the inner diameter of the second liner neck; 
 a second swage recess, wherein the second swage recess comprises an outer diameter that is less than the inner diameter of the second liner neck; 
   wherein the second port is configured to press-fit into the second liner neck, wherein the second lip is configured to provide a surface area to weld the second port to the second liner neck, wherein the second swage recess is configured to provide an area to swage the second liner neck to the second port.   
     
     
         3 . The composite cylinder assembly of  claim 1 , wherein the tube liner comprises a carbon fiber overwrap, wherein the carbon fiber overwrap further comprises a glass fiber layer. 
     
     
         4 . The composite cylinder assembly of  claim 1 , wherein the tube liner is made of metal. 
     
     
         5 . The composite cylinder assembly of  claim 1 , wherein the cylindrical wall of the tube liner is seamed. 
     
     
         6 . The composite cylinder assembly of  claim 1 , wherein the tube liner is spin welded. 
     
     
         7 . The composite cylinder assembly of  claim 2 , wherein each port defines a channel. 
     
     
         8 . The composite cylinder assembly of  claim 7 , wherein the channel is substantially cylindrical, wherein the channel is threaded. 
     
     
         9 . The composite cylinder assembly of  claim 2 , wherein each liner neck is stoppered at the port lip. 
     
     
         10 . The composite cylinder assembly of  claim 2 , wherein each liner neck is spin welded to the port lip. 
     
     
         11 . The composite cylinder assembly of  claim 2 , wherein each liner neck is fusion welded to the port lip. 
     
     
         12 . A composite cylinder assembly, comprising:
 a tube liner, wherein the tube liner comprises:
 a domed head portion, wherein the domed head portion defines a liner neck; 
 an open bottom portion; and 
 a cylindrical wall coupled to the domed head portion and the open bottom portion, wherein the cylindrical wall is between the domed head portion and the open bottom portion; and 
   a mandrel port, wherein the mandrel port comprises an outer diameter configured to fit into an inner diameter of the liner neck, wherein the mandrel port defines a channel, wherein the mandrel port further comprises a mandrel, wherein the mandrel comprises an outer diameter that is greater than the inner diameter of the liner neck, wherein the mandrel port is configured to press-fit into the liner neck, wherein the mandrel port is configured to be welded to the liner neck.   
     
     
         13 . The composite cylinder assembly of  claim 12 , wherein the tube liner further comprises a mandrel spindle, wherein the mandrel spindle is welded to the open bottom portion, wherein the mandrel spindle is configured to seal the open bottom portion. 
     
     
         14 . The composite cylinder assembly of  claim 12 , wherein the mandrel port is a short mandrel port comprising a bisecting mandrel. 
     
     
         15 . The composite cylinder assembly of  claim 12 , wherein the mandrel port is a long mandrel port comprising a terminal mandrel. 
     
     
         16 . The composite cylinder assembly of  claim 12 , wherein the mandrel corresponds to a convex contour of an inner surface of the domed head portion. 
     
     
         17 . A method of manufacturing a composite cylinder assembly, comprising:
 forming a tube liner, wherein the tube liner comprises:
 a first domed portion, wherein the first domed portion defines a first liner neck; 
 a second domed portion, wherein the second domed portion defines a second liner neck; and 
 a cylindrical wall coupled to the first domed portion and the second domed portion, wherein the cylindrical wall is between the first domed portion and the second domed portion; 
   fabricating a first port, wherein the first port comprises an outer diameter configured to fit into an inner diameter of the first liner neck, wherein the first port comprises:
 a first lip, wherein the first lip comprises an outer diameter that is greater than the inner diameter of the first liner neck; and 
 a first swage recess, wherein the first swage recess comprises an outer diameter that is less than the inner diameter of the first liner neck; 
   press-fitting the first port into the first liner neck;   swaging the first liner neck to the first port at the first swage recess; and   welding the first port to the first liner neck at the first lip.   
     
     
         18 . The method of  claim 17 , further comprising:
 fabricating a second port, wherein the second port comprises an outer diameter configured to fit into an inner diameter of the second liner neck, wherein the second port comprises:
 a second lip, wherein the second lip comprises an outer diameter that is greater than the inner diameter of the second liner neck; and 
 a second swage recess, wherein the second swage recess comprises an outer diameter that is less than the inner diameter of the second liner neck; 
   press-fitting the second port into the second liner neck;   swaging the second liner neck to the second port at the second swage recess; and   welding the second port to the second liner neck at the second lip.   
     
     
         19 . The method of  claim 17 , wherein the forming comprises metal spinning the tube liner. 
     
     
         20 . The method of  claim 17 , wherein the forming comprises deep drawing the first domed portion and the second domed portion, wherein the forming further comprises fusion welding the first domed portion to the second domed portion to form the cylindrical wall, wherein the cylindrical wall comprises a fusion weld line along a girth of the cylindrical wall.